Shielded cable system for the shielding and protection against emi-leakage and impedance control

ABSTRACT

The cable attaches a first component and a second component using a quick disconnect connector pair. The cable includes a twisted pair of wires with a separate shield. A portion of the shielding near the connector is removed to expose the wires and assemble the wires to the connector. To reduce the EMI leakage, the inner shell encloses the exposed portions of the wires. In order to maintain the ground path for the shielding of the shielded twisted wire pairs, the shielding for the twisted wire pairs is connected to the shell. The outer shells facilitate the quick disconnect feature. The outer shell includes one or more slots. The slot allows a portion of the outer shell to become a cantilever beam. The beam deflects during disengagement and engagement with the outer shell.

BACKGROUND OF THE INVENTION

Electrical cables are used to connect various electrical and electroniccomponents. In addition, electrical cables may need to satisfy certainelectrical characteristics, such as, impedance or ElectromagneticInterference (“EMI”) leakage and physical characteristics, such as, sizeor weight. Also, electrical cables may need to be disconnected from theelectrical components. The invention relates to a new cable system.

BRIEF SUMMARY OF THE INVENTION

The invention provides a cable which may be attached to a firstcomponent and a second component. In one embodiment, the first componentmay be a helmet to be worn by a pilot or driver. In one embodiment, thesecond component is a control box. The cable may include a firstconnector pair. In one embodiment, the first connector pair may be aquick disconnect connector pair. The first connector pair may include afirst connector and a second connector. For example, the user of thefirst component (for example, helmet) may use the connector to connectand disconnect from the second component (for example, control box) whenthe user enters and exits the vehicle.

The cable may include wires or conductors. In one embodiment, the cablemay include nineteen wires to transmit signals and/or power. In otherembodiments, the cable may include fiber optic conductors, or othertypes of conductors.

In one embodiment, the wires may include a twisted pair of wires. Thetwisted pair of wires may have a separate shield. The twisted pair ofwires with the shield may provide controlled impedance for the wires. Inone embodiment the cable may have six pairs of the shielded twisted wirepair assemblies.

When the shielded twisted wire pair assemblies are assembled to theconnector, a portion of the shielding near the connector may be removedto expose the wires. When the shielding is separated from the shieldedtwisted wire pair assembly, portions of the wires do not have theshielding. These exposed portions may cause EMI leakage. To reduce theEMI leakage, the inner shell encloses the exposed portions of the wires.The inner shell extends to cover the exposed portions of the wires.

In order to maintain the ground path for the shielding of the shieldedtwisted wire pairs, the shielding is connected to the shell. Theshielding is connected to the shell to maintain the ground along thesignal paths for the wires. In one embodiment, the shielding for eachwire pair can share the same ground path. Thus, the shielding for eachshielded wire pair can be connected to the shell.

The cable may include a shielding layer. The shielding layer may reduceor eliminate EMI leakage. In one embodiment, a separating layer may bepositioned between the shielded twisted wire pair assemblies and theshielding layer.

The connector may include an outer shell. The outer shell may shield theconnector. The shielding layer may be connected to the outer shell. Theconnection of the shielding layer with the outer shell will createshielding along the cable.

The connector may include an insulator between the outer shell and theinner shell to insulate the shielding from the ground path.

The connector pair may be a quick disconnect connector. The connectorand connector may disconnect at 10-15 pounds. The outer shellsfacilitate the quick disconnect feature. The outer shell includes one ormore slots. The slots allow a portion of the outer shell to become acantilever beam. The beams are allowed to deflect during disengagementand engagement with the outer shell. The deflection can be used tocontrol the amount of disconnect force.

The cable may have additional wires. The additional wires may be locatedcloser to the center of the cable than the shielded twisted wire pairassemblies. In one embodiment, the additional wires may be a combinationof twisted pairs and individual wires. For example, in an embodimentwith seven additional wires, the combination may be a single wire andthree twisted pairs of wires.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is a perspective view of the cable attached to a helmet and acontrol box.

FIG. 2 is a perspective view of another embodiment of the cable.

FIG. 3 is a top view of the cable and connectors in FIG. 1 with thecable disconnected at the connectors.

FIG. 4 is a top view similar to FIG. 3 but the cable is connected at theconnectors.

FIG. 5 is a cross-sectional view along line 5-5 in FIG. 4.

FIG. 6 is a cross-sectional view along line 6-6 in FIG. 3.

FIG. 7 is a cross-sectional view along line 7-7 in FIG. 4.

FIG. 8 is an enlarged cross-sectional view.

FIG. 9 is a perspective view of the termination of the cable.

FIG. 10 is a perspective view of the female end of quick disconnectconnector.

FIG. 11 is a rear perspective view of another embodiment of theconnector.

FIG. 12 is a front perspective view of the embodiment in FIG. 11.

FIG. 13 is a perspective view of the male end of quick disconnectconnector.

FIG. 14 is a cross-sectional view of the outer shells.

FIG. 15 is a cross-sectional view along line 15-15 in FIG. 3.

FIG. 16 is a cross-sectional view along line 16-16 in FIG. 4.

FIG. 17 is a cross-sectional view along line 17-17 in FIG. 3.

FIG. 18 is a cross-sectional view along line 18-18 in FIG. 4.

DESCRIPTION OF THE INVENTION

Referring to FIG. 1, the cable 100 is shown. In one embodiment, thecable 100 is attached to a first component 102 and a second component104. In one embodiment, the first component 102 may be a helmet to beworn by a pilot or driver. In other embodiments, the component 102 maybe control system, an interface panel, or other component. In oneembodiment, the second component 104 is a control box. The control boxmay be attached to the vehicle. In other embodiments, the component 104may be an interface panel, or other component.

The cable 100 may include a first connector pair 106. In one embodiment,the first connector pair 106 may be a quick disconnect connector pair.The first connector pair 106 may include a first connector 108 and asecond connector 110. The first connector 108 may be connected anddisconnected from the second connector 110. In one embodiment, theconnector 106 may be used to connect and disconnect the first component102 from the second component 104. For example, the user of the firstcomponent 102 (for example, helmet) may use the connector 106 to connectand disconnect from the second component 104 (for example, control box)when the user enters and exits the vehicle. The connector pair 106 mayhave a disconnecting force of 10-15 pounds.

The cable 100 may be connected to the first component 102 with a secondconnector pair 116. The second connector pair 116 may include a thirdconnector 118 and a fourth connector 120. In one embodiment, the secondconnector pair 116 may be a Nano-D connector pair.

The cable 100 may include a first wire assembly 112. The first wireassembly 112 is connected to the first connector 108 and the thirdconnector 118.

The cable 100 may be connected to the second component 104 with a thirdconnector pair 126. The third connector pair 126 may include a fifthconnector 128 and a sixth connector 130. In one embodiment, the thirdconnector pair 126 may be a 38999 connector pair.

The cable 100 may include a second wire assembly 114. The second wireassembly 114 is connected to the second connector 110 and the fifthconnector 128.

Referring to FIG. 2, another embodiment of the cable is shown. The cable300 may include additional first connector pairs. The cable 300 mayinclude a first connector pair 306 which may be similar to firstconnector pair 106. The cable 300 may include fourth connector pair 307which may be similar to first connector pair 306. Fourth connector pair307 may have a higher disconnecting force than first connector pair 306.First connector pair 306 may have a disconnecting force of 10-15 pounds.Fourth connector pair 307 may have a disconnecting force of 40-50pounds. The cable 300 may include fifth connector pair 309 which may besimilar to first connector pair 306. Fifth connector pair 309 may have ahigher disconnecting force than first connector pair 306. Fifthconnector pair 309 may have a disconnecting force of 40-50 pounds. Firstconnector pair 306 may have a disconnecting force of 10-15 pounds. Fifthconnector pair 309 may include a bracket 311. The bracket 311 may beused to attach to a mating bracket. In one embodiment, the matingbracket may be on the user's clothing. In one embodiment, the bracketmay be on the user's belt.

Referring to FIG. 3, the cable 100 is shown with the cable disconnectedat the connectors. The cable 100 is disconnected at the first connectorpair 106. Specifically, the first connector 108 is disconnected from thesecond connector 110. The cable is also disconnected at the secondconnector pair 116. Specifically, the third connector 118 isdisconnected from the fourth connector 120. The cable is alsodisconnected at the third connector pair 126. Specifically, the fifthconnector 128 is disconnected from the sixth connector 130.

Referring to FIG. 4, the cable 100 is shown with cable connected at theconnectors. The cable 100 is connected at the first connector pair 106.Specifically, the first connector 108 is connected to the secondconnector 110. The cable is also connected at the second connector pair116. Specifically, the third connector 118 is connected to the fourthconnector 120. The cable is also connected at the third connector pair126. Specifically, the fifth connector 128 is connected to the sixthconnector 130.

Referring to FIG. 5, the cable 100 may include wires or conductors 138.In one embodiment, the wires may include a conductive portion and aninsulation material over the conductive portion. In one embodiment, thecable may include nineteen wires or conductors 140-158. In anotherembodiment, the cable may include 25 wires. In other embodiments, thecable may include 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16,17, 18, 20, 21, 22, 23, 24, 26 or more wires. In other embodiments, thecable may include fiber optic conductors, or other types of conductorsto transmit signals and/or power.

Referring to FIG. 5, in one embodiment, the wires may include a twistedpair of wires 140, 141. The twisted pair of wires 140, 141 may have aseparate shield 160. The twisted pair of wires 140, 141 and the separateshield 160 are assembled into a shielded twisted wire pair assembly 170.The shield 160 surrounds the twisted pair of wires 140, 141. The twistedpair of wires with the shield may provide controlled impedance for thewires 140, 141. In one embodiment, the shield may be a tubular shield.In one embodiment, the shield may be a braided shield. The braidedshield may be formed by weaving metal threads to create the shieldingmaterial.

In one embodiment the cable may have six pairs of the shielded twistedwire pair assemblies. For example, the cable may include a secondshielded twisted wire pair assembly 171 with a second twisted wire pair142, 143 and shield 161, a third shielded twisted wire pair assembly 172with a third twisted wire pair 144, 145 and shield 162, a fourthshielded twisted wire pair assembly 173 with a fourth twisted wire pair146, 147 and shield 163, a fifth shielded twisted wire pair assembly 174with a fifth twisted wire pair 148, 149 and shield 164, and a sixthshielded twisted wire pair assembly 175 with a sixth twisted wire pair150, 151 and shield 165. In other embodiments, the cable may have 1, 2,3, 4, 5, 7, or more pairs of the shielded twisted wire pair assemblies.The shielded twisted wire pair assemblies 170-175 may be located on theperimeter of the cable 100. In one embodiment, the shielded twisted wirepairs may be 28 AWG wire size.

Referring to FIG. 5, the cable may have wires 152-158. The wires 152-158may be located toward the center of the cable. The wires 152-158 may belocated closer to the center of the cable than the shielded twisted wirepair assemblies 140-151. The shielded twisted wire pair assemblies140-151 may be located further from the center of the cable than thewires 152-158. The wires may transmit signals or power. In oneembodiment, the cable may have seven wires 152-158. In otherembodiments, the cable may have 1, 2, 3, 4, 5, 6, 8, or more wires. Inone embodiment, the wires may be twisted pairs. In one embodiment, thewires may be a combination of twisted pairs and individual wires. Forexample, in an embodiment with seven wires, the combination may be asingle wire 158 and three twisted pairs of wires 152-157. Otherembodiments may have other combinations, such as: three single wires andtwo twisted pairs; or five single wires and one twisted pair.

Referring to FIG. 5, in one embodiment the cable may have six pairs ofshielded twisted wire pair assemblies 140-151 and seven wires 152-158.In other embodiments, the cable may have any combination of 1, 2, 3, 4,5, 6, or 7 more pairs of shielded twisted wire pair assemblies and 1, 2,3, 4, 5, 6, 7, 8 or more non-shielded wires.

Referring to FIG. 5, the twisted pair 152, 153 may be covered with acovering 180. In one embodiment, the cable may include a second twistedpair of wires 154, 155 and a covering 181. In an additional embodiment,the cable may include a third twisted pair of wires 156, 157 and acovering 182. In one embodiment, the covering may be a Teflon tape. Inone embodiment, two of the twisted pairs 152-155 may be 24 AWG wiresize, one twisted pair 156, 157 may be 28 AWG wire size, and the singlewire 158 may be 28 AWG wire size.

The cable may include one or more filler strands. The filler strands mayassist in maintaining the spacing among the wires 140-151, wires152-157, and wire 158. In one embodiment, the cable may include ninefiller strands 190-198. The filler strands may be made of LSNW (LowShrink Non-Wick) polyester. In other embodiments, the filler strands maybe made of other materials.

Referring to FIG. 5, the cable may include a covering 210 over thewires. In one embodiment, the covering 210 may be a Teflon tape. Thecable may include another covering 212. In one embodiment, the covering212 may be a Kevlar braid.

Referring to FIG. 5, the cable may include a shielding layer 214. Theshielding layer 214 may reduce or eliminate EMI leakage. In oneembodiment, the shielding layer 214 may be shielding braid. In oneembodiment, the shielding layer 214 does not make contact with theshielded twisted wire pair assemblies 170-175. The shielded twisted wirepair assemblies 170-175 may be isolated from the shielding layer 214. Inone embodiment, a separating layer may be positioned between theshielded twisted wire pair assemblies 170-175 and the shielding layer214. The separating layer may prevent contact between the shieldedtwisted wire pair assemblies 170-175 and the shielding layer 214. Theseparating layer may also isolate the shielded twisted wire pairassemblies 170-175 from the shielding layer 214.

In one embodiment, the separating layer may be the covering 160-165. Inanother embodiment, the separating layer may be the covering 210. Infurther embodiment, the separating layer may be the covering 212. In anadditional embodiment, the separating layer may be one or more of thecovering 160-165, covering 210, or covering 212.

Referring to FIG. 5, the cable may include an outer covering 216. In oneembodiment, the outer covering 216 may be braided. In one embodiment,the outer covering 216 may be made of a material which isfire-resistant. For example, the covering 216 may be made of Nomex. Inone embodiment, the Nomex may be braided.

Referring to FIGS. 6 and 8, the shielding layer 214 may be attached tothe connector. In one embodiment, the shielding layer 214 may beattached with a band clamp 220. In other embodiments, the shieldinglayer 214 may be attached using other techniques.

The cable may include a strain relief boot 222 which may be attached tothe connector. In one embodiment, the strain relief boot 222 may beattached with a band clamp 224. In other embodiments, the strain reliefboot may be attached using other techniques. The band clamp 224 may havea covering 226. In one embodiment, the covering 226 may be heat shrinktubing. In other embodiments, the covering 226 may be other materials.

FIG. 6 is a cross-sectional view of the connector pair 106 taken alongline 6-6 in FIG. 3. Referring to FIG. 6, the first connector 108 mayinclude a contact 230. In one embodiment, the contact may be a pincontact or a female contact. The contact 230 may be attached to a wire.The wire may be one of the wires 140-158. Wire 140 will be used as anexample for the following discussion. The wire 140 may include aninsulation material over the conductive portion of the wire. A portionof the insulation may be removed at the location where the contact 230is attached to the wire. The wire 140 may be attached by crimping thecontact 230 onto the portion of the wire without insulation. In anotherembodiment, the wire may be soldered to the contact. In an additionalembodiment, the wire may be attached to the contact by anotherconnection technique.

Referring to FIG. 10, the connector 108 may include nineteen contacts230. In other embodiments, the connector may have more or less thannineteen contacts.

The size of the contact 230 depends upon the intended use of the cable.In one embodiment, the contact 230 is sized for use with 24 AWG sizewire. In another embodiment, the contact 230 may be sized for use with28 AWG size wire. In other embodiments, the contact and wire may belarger or smaller than the 24 AWG size or 28 AWG size.

Referring to FIG. 6, the connector 108 may include an insulator 232. Theinsulator 232 holds the contacts 230 and prevents the contacts fromcontacting each other. Referring to FIG. 10, the insulator 232 mayinclude apertures 234 and the contacts 230 are positioned in theapertures 234. In one embodiment, the insulator 232 may include nineteenapertures 234. In other embodiments, the insulator may have more or lessthan nineteen apertures depending upon the number of contacts. The sizeof the aperture depends upon the size of the contact 230. In oneembodiment, the contact may be retained in the aperture by epoxy. Asmall amount of epoxy may be applied to hold the contact into theaperture. In one embodiment, the insulator and the contact may includeretention features which retain the contact in the insulator in apermanent manner, or non-permanent manner.

Referring to FIG. 6, the connector 108 may include a grounding shell236. In one embodiment, the shell may be made of metal. In otherembodiments, the shell may be made from other materials which mayprovide the EMI shielding as discussed herein. The insulator 232 will bepositioned inside the shell 236.

Referring to FIG. 6, the shell 236 may include openings which exposeportions of the insulator 232. The openings in the shell may provideaccess to the apertures 234 in the insulator 232. Referring to FIG. 6,the shell 236 may include a front opening 238. The front opening 238provides access to the apertures 234. Referring to FIG. 6, the shell 236may include a rear opening 240. The rear opening 240 provides access tothe apertures 234.

When the connector is assembled onto the cable, the wires from the cablemay be inserted into the apertures 234. The contact 230 may be attachedto the wire prior to insertion into the aperture 234. In one embodiment,the contact 230 with the attached wire is inserted into the rear of theaperture 234.

Referring to FIG. 8, when the shielded twisted wire pair assemblies areassembled to the connector, a portion of the shielding near theconnector may be removed to expose the wires. For example, a portion ofthe shielding 160 is removed to expose the wire pair 140, 141. Theexposed portion of the wires 140, 141 is designated as 242, 244. FIG. 9also shows the shielding 160 and the exposed portions 242, 244 of thewires 140, 141. Preferably, the least amount of shielding should beremoved in order to reduce or eliminate EMI leakage. When the shieldingis separated from the shielded twisted wire pair assembly, portions ofthe wires do not have the shielding. These exposed portions may causeEMI leakage. To reduce the EMI leakage, the shell encloses the exposedportions of the wires. As shown in FIG. 8, the shell 236 extends tocover the exposed portions of the wires. The exposed portions 242, 244will be used as an example. If the rear edge 246 of the shell is used todefine a plane 248, the exposed portions 242, 244 of the wires arelocated inside the plane 248 of the shell.

In order to maintain the ground path for the shielding of the shieldedtwisted wire pairs, the shielding is connected to the shell. Theshielding is connected to the shell 236 to maintain the ground along thesignal paths for the wires. In one embodiment, the shielding for eachwire pair can share the same ground path. Thus, the shielding for eachshielded wire pair can be connected to the shell 236.

In one embodiment, a wire may be used to connect the shielding to theshell. Referring to FIGS. 8 and 9, the wire 250 may have a first end 252and a second end 254. The first end 252 of the wire may be connected tothe shielding 160. The second end 254 of the wire may be connected tothe shell 236. In one embodiment, the wire may be connected bysoldering. In other embodiments, the wire may be connected by mechanicalretention, or other techniques.

In another embodiment, a portion of the shielding may be separated fromthe shielded twisted wire pair assembly. The separated portion of theshielding may be connected to the shell. In one embodiment, a threadfrom the braided shielding may be unwoven from the braid. The thread maybe connected to the shell. In one embodiment, the thread may beconnected by soldering the thread to the shell. In other embodiments,the thread may be retained by other techniques, such as, mechanicalretention. In one embodiment, two threads may be unwoven from the braid.The two threads may be connected to the shell. The threads may beconnected by soldering, mechanical retention or other technique.

Referring to FIGS. 11 and 12, another embodiment of the shell andinsulator is shown. The shell 436 may include one or more openings 439which expose portions of the insulator 432. The openings 439 in theshell may provide access to the apertures 434 in the insulator 432. Thewires from the shielded twisted wire pair assemblies may be insertedinto the apertures 434. The contact 435 may be attached to the wireprior to insertion into the aperture 434.

As noted herein, in order to maintain the ground path for the shielding,the shielding is connected to the shell. In one embodiment, a wire 450may be used to connect the shielding 460 to the shell 436 as shown inFIG. 11. The wire 450 may have a first end 452 and a second end 454. Thefirst end 452 of the wire may be connected to the shielding 460. Thesecond end 454 of the wire may be connected to the shell 436. In oneembodiment, the wire may be connected by soldering. In otherembodiments, the wire may be connected by mechanical retention, or othertechniques. In one embodiment, the second end 454 of the wire may beinserted into an opening 455 in the shell 436 and then connected bysolder, mechanical retention, or other technique.

In another embodiment, a portion of the shielding may be separated fromthe shielded twisted wire pair. The separated portion may be connectedto the shell. In one embodiment, a thread from the braided shielding maybe unwoven from the braid. The thread may be inserted into an opening inthe shell. The opening may include a chamfered leading edge tofacilitate the insertion of the thread into the opening. The thread maybe retained in the opening. In one embodiment, the thread may beretained by soldering the thread in the opening. In other embodiments,the thread may be retained by other techniques, such as, mechanicalretention. In one embodiment, two threads may be unwoven from the braid.The two threads may be inserted into two openings. The threads may beretained in the openings.

An epoxy may be applied to the rear of the connector after the wire andground connections have been completed.

Referring to FIGS. 6 and 8, the connector 108 may include an outer shell260. The outer shell 260 may be used to connect the connector 108 to theconnector 110. The connection between connector 108 and connector 110may be a quick disconnect connection as will be discussed herein.

The outer shell 260 may shield the connector. As noted herein, theshielding layer 214 may be connected to the outer shell 260. Theconnection of the shielding layer 214 with the outer shell will createshielding along the cable. In one embodiment, the shielding layer 214 isconnected to the outer shell 260 with band clamp 220.

The connector 108 may include an insulator between the outer shell andthe inner shell to insulate the shielding from the ground path. In oneembodiment, the connector may include insulator 262 as shown in FIGS. 6and 8. The insulator 262 insulates the inner shell 236 from the outershell 260.

The connector may include a ground contact. In one embodiment, theground contact may be a ground spring 264 which is shown in FIGS. 8 and10. In one embodiment, the ground spring may be a serpentine groundspring. The ground contact may facilitate or make the connection betweenthe shell in connector 108 and connector 110.

The connector may include an orientation feature. In one embodiment, theorientation feature may be one or more keys 266 which are shown in FIG.10. The keys 266 may mate with slots in connector 110. The orientationfeature is used to obtain the proper orientation of the connectors 108,110 during mating.

Referring to FIG. 6, the second connector 110 is similar to the firstconnector 108 except for changes to allow the connectors 108, 110 tomate together. Connector 110 uses female contacts 530 to connect withthe male contacts 230 as shown in FIG. 13. Referring to FIG. 6, aninsulator 532 holds the female contacts 530.

The shell 536 of the connector 110 mates with shell 236. A groundcontact 264 may be used to make the connection between the shell 536 andthe shell 236.

The connector 110 may include an insulator 562 to maintain the spacingbetween the inner shell 536 and the outer shell 560. The shielding layerof the cable may be connected to the outer shell 560 with band clamp520.

The connector 110 may include an O-ring 563. The O-ring 563 may providean environmental seal.

The connector 110 may include an orientation feature. In one embodiment,the orientation feature may be one or more slots 566 which are shown inFIG. 13. The slots 566 may mate with the keys 266 in connector 108 whichare shown in FIG. 10.

Referring to FIG. 6, the connector 110 may include other componentswhich are the same as in connector 108 including the strain relief boot522, the band clamp 524, and the covering 526.

The connections of the wires and shielding for connector 110 would bethe same as for connector 108.

The connector pair 106 may be a quick disconnect connector. Referring toFIG. 6, the connector 108 and connector 110 may disconnect at 10-15pounds. The outer shells 260, 560 facilitate the quick disconnectfeature. Referring to FIG. 10, the outer shell 260 includes one or moreslots 270. In one embodiment, the shell includes 8 slots. In otherembodiments, the outer shell may include 1, 2, 3, 4, 5, 6, 7, 9 or moreslots. The slots 270 allow a portion of the outer shell to become acantilever beam 272 as shown in FIGS. 10 and 14. In one embodiment, theouter shell 260 may have eight-cantilever beams 272. In otherembodiments, the outer shell may have 1, 2, 3, 4, 5, 6, 7, 9 or morebeams.

The beams 272 are allowed to deflect during disengagement and engagementwith the outer shell. The deflection can be used to control the amountof disconnect force. Other factors may also influence the disconnectforce including material thickness, material composition, travel andexit angles. The designer would consider these factors to design shellswith the desired disconnection force.

Referring to FIGS. 6 and 14, the outer shell 260 may include a latchingprotrusion 274. The protrusion 274 may be on one or more of the beams272. In one embodiment, the protrusion may be on all of the beams. Inone embodiment, the protrusion 274 may be located near the end of thebeam. In other embodiments, the protrusion may be located in a differentposition.

The outer shell 560 may include a ramp 576. A portion of the outer shell260 may engage the ramp 576 when the outer shell 260 and the outer shell560 are mated. The engagement may cause the beam 272 to deflect. In oneembodiment, the protrusion 274 may engage the ramp 576.

The outer shell 560 may include a detent 578. In one embodiment, thedetent 578 may be a groove. The detent 578 may include a ramp 580. Whenthe outer shell 260 and the outer shell 560 are mated, the protrusion274 may engage the detent 578. The engagement may hold the outer shells260, 560 together until the specified disconnection force is applied.When the specified disconnection force is applied, the beam 272 willdeflect and allow the protrusion 274 and detent 578 to disengage.

Referring to FIGS. 15 and 16, the connector 118 and connector 120 areshown. The connector 118 may be a Nano plug connector and the connector120 may be a Nano socket connector.

The connector 118 may include contacts 630, an insulator 632, a plugshell 636, a backshell 660, epoxy 661, a band clamp 620, and covering621. The wires are connected to the contacts 630. The wire and contactassembly is then inserted into the insulator 632. In one embodiment, theshield for the shielded twisted wire pair may be connected to a contact630 which may be a ground contact. For example, the shield 160 for wirepair 140, 141 as shown in FIG. 5 may be connected to a contact 630. Theshield may be connected to the contact with a soldered wire, with aportion of the shield, or with another technique. The insulator 632 isinserted onto the plug shell 636. The plug shell 636 is inserted intothe backshell 660. An epoxy 661 is applied to the rear of the connector.The shielding layer 214 is connected to the backshell 660 with a bandclamp 620. A covering 621 is applied over the band clamp 620. Thecovering 621 may be a heat shrink tubing.

The connector 120 may include male contacts 730, an insulator 732, ashell 736 and epoxy 761. The contacts 730 are attached to the insulator732. The insulator 732 is inserted into the shell 736. An epoxy 761 isapplied to the rear of the shell 736.

Referring to FIG. 16, the connector 118 may be connected to theconnector 120.

Referring to FIGS. 17 and 18, the connector 128 and connector 130 areshown. The connector 128 may be a 38999 plug connector and the connector130 may be a 38999 socket connector.

The connector 128 may include female contacts 830, an insulator 832, ashell 836, a ground contact 864, an insulator 862, a plug shell 860, abackshell 865, a band clamp 820, a strain relief boot 822, a band clamp824, a covering 826, and epoxy 861. The wires are connected to thecontacts 830. The wire and contact assembly is then inserted into theinsulator 832. The insulator 832 may be located inside the inner shell836. The shield for the shielded twisted wire pairs may be attached tothe inner shell 836 using the various techniques and embodimentsdiscussed above with respect to the shell 236 and the shell 436. Theinner shell 836 may include a ground contact 864. An epoxy 861 may beapplied to the inner shell 836. An insulator 862 may be located betweenthe inner shell 836 and the outer shell 860. A backshell 865 may beattached to the outer shell 860. The shielding layer 214 may beconnected to the backshell 865 with a band clamp 820. A strain reliefboot 822 may be attached with a band clamp 824. A covering 826 may belocated over the band clamp 824. The connector 128 may include acircular nut 867 which may engage the connector 130.

The connector 130 may include male contacts 930, an insulator 932, ashell 936, an insulator 962, an outer shell 960, a gasket 963, and epoxy961. The contacts 930 are located inside the insulator 932. Wires 965may be connected to the contacts 930. The insulator 932 may be locatedinside the shell 936. One or more ground wires 967 may be connected tothe inner shell 936. An insulator 962 may be located between the innershell 936 and the outer shell 960. An epoxy 961 may be applied to therear of the connector. The connector may include a gasket 963.

Referring to FIG. 18, the connector 128 may be connected to theconnector 130. The circular nut 867 may be threaded onto the connector130.

All references, including publications, patent applications, andpatents, cited herein are hereby incorporated by reference to the sameextent as if each reference were individually and specifically indicatedto be incorporated by reference and were set forth in its entiretyherein.

The use of the terms “a” and “an” and “the” and “at least one” andsimilar referents in the context of describing the invention (especiallyin the context of the following claims) are to be construed to coverboth the singular and the plural, unless otherwise indicated herein orclearly contradicted by context. The use of the term “at least one”followed by a list of one or more items (for example, “at least one of Aand B”) is to be construed to mean one item selected from the listeditems (A or B) or any combination of two or more of the listed items (Aand B), unless otherwise indicated herein or clearly contradicted bycontext. The terms “comprising,” “having,” “including,” and “containing”are to be construed as open-ended terms (i.e., meaning “including, butnot limited to,”) unless otherwise noted. Recitation of ranges of valuesherein are merely intended to serve as a shorthand method of referringindividually to each separate value falling within the range, unlessotherwise indicated herein, and each separate value is incorporated intothe specification as if it were individually recited herein. All methodsdescribed herein can be performed in any suitable order unless otherwiseindicated herein or otherwise clearly contradicted by context. The useof any and all examples, or exemplary language (e.g., “such as”)provided herein, is intended merely to better illuminate the inventionand does not pose a limitation on the scope of the invention unlessotherwise claimed. No language in the specification should be construedas indicating any non-claimed element as essential to the practice ofthe invention.

Preferred embodiments of this invention are described herein, includingthe best mode known to the inventors for carrying out the invention.Variations of those preferred embodiments may become apparent to thoseof ordinary skill in the art upon reading the foregoing description. Theinventors expect skilled artisans to employ such variations asappropriate, and the inventors intend for the invention to be practicedotherwise than as specifically described herein. Accordingly, thisinvention includes all modifications and equivalents of the subjectmatter recited in the claims appended hereto as permitted by applicablelaw. Moreover, any combination of the above-described elements in allpossible variations thereof is encompassed by the invention unlessotherwise indicated herein or otherwise clearly contradicted by context.

Particular embodiments of the present invention are the following:

-   -   1. An electrical cable assembly comprising:        -   an electrical cable, the cable including:        -   a first twisted pair of electrical wires, the electrical            wires conduct electrical signals;        -   a first shield covering the first twisted pair of electrical            wires;        -   a second twisted pair of electrical wires, the electrical            wires conduct electrical signals;        -   a second shield covering the second twisted pair of            electrical wires;        -   an electrical connector including:        -   electrical contacts, the electrical contacts conduct            electrical signals, the electrical contacts connected to the            electrical wires;        -   an insulator, the insulator holds the electrical contacts;        -   a grounding shell, the first shield and the second shield            are connected to the grounding shell.    -   2. The electrical cable assembly of embodiment 1 wherein the        first shield is connected to the grounding shell with a        grounding wire.    -   3. The electrical cable assembly of embodiment 2 wherein the        grounding wire is connected to the first shield by soldering and        the grounding wire is connected to the grounding shell by        soldering.    -   4. The electrical cable assembly of embodiment 1 wherein a        portion of the first shield is connected to the grounding shell.    -   5. The electrical cable assembly of embodiment 4 wherein the        portion of the first shield is connected to the grounding shell        by soldering.    -   6. The electrical cable assembly of embodiment 1 wherein the        connector includes a second shell, the second shell provides        shielding.    -   7. The electrical cable assembly of embodiment 6 wherein an        insulator is located between the grounding shell and the second        shell.    -   8. The electrical cable assembly of embodiment 6 wherein the        cable includes an outer shield which covers the first twisted        pair of electrical wires, the first shield, the second twisted        pair of electrical wires and the second shield.    -   9. The electrical cable assembly of embodiment 8 wherein the        outer shield is connected to the second shell.    -   10. The electrical cable assembly of embodiment 1 wherein the        electrical cable includes one or more wires.    -   11. The electrical cable assembly of embodiment 10 wherein the        cable has a center, the one or more wires are located closer to        the center than the first twisted pair of electrical wires.    -   12. The electrical cable assembly of embodiment 10 wherein the        one or more wires are a third twisted pair of electrical wires.    -   13. The electrical cable assembly of embodiment 1 wherein the        cable includes a fire resistant covering for the wires.    -   14. The electrical cable assembly of embodiment 1 wherein the        cable includes filler strands.    -   15. An electrical cable assembly comprising:        -   an electrical cable, the cable including:        -   a first twisted pair of electrical wires, the electrical            wires conduct electrical signals;        -   a first shield covering the first twisted pair of electrical            wires;        -   an electrical connector including:        -   electrical contacts, the electrical contacts to conduct            electrical signals, the electrical contacts connected to the            electrical wires;        -   an insulator, the insulator holds the electrical contacts;        -   a grounding shell, the grounding shell has a rear portion            and the rear portion defines a rear boundary;        -   a portion of the first shield is removed to terminate the            first twisted pair of electrical wires to the contacts and            the first twisted pair of electrical wires have portion            which is not shielded by the first shield,        -   the unshielded portion of the wires is within the rear            boundary of the grounding shell.    -   16. The electrical cable of embodiment 15 wherein the first        shield is connected to the grounding shell.    -   17. The electrical cable assembly of embodiment 15 wherein the        cable includes a second twisted pair of electrical wires, the        electrical wires conduct electrical signals; a second shield        covering the second twisted pair of electrical wires, a portion        of the second shield is removed to terminate the second twisted        pair of electrical wires to the contacts and the second twisted        pair of electrical wires have a portion which is not shielded by        the second shield, the unshielded portion of the second twisted        pair of electrical wires is within the rear boundary of the        grounding shell.    -   18. The electrical cable assembly of embodiment 17 wherein the        second shield is connected to the grounding shell.    -   19. The electrical cable assembly of embodiment 15 wherein the        connector includes a second shell, the second shell provides        shielding.    -   20. The electrical cable assembly of embodiment 19 wherein an        insulator is located between the grounding shell and the second        shell.    -   21. The electrical cable assembly of embodiment 19 wherein the        cable includes an outer shield which covers the first twisted        pair of electrical wires, the first shield, the second twisted        pair of electrical wires and the second shield.    -   22. The electrical cable assembly of embodiment 21 wherein the        outer shield is connected to the second shell.    -   23. The electrical cable assembly of embodiment 15 wherein the        electrical cable includes one or more wires.    -   24. The electrical cable assembly of embodiment 15 wherein the        electrical cable includes one or more wires.    -   25. The electrical cable assembly of embodiment 24 wherein the        cable has a center, the one or more wires are located closer to        the center than the first twisted pair of electrical wires.    -   26. The electrical cable assembly of embodiment 24 wherein the        one or more wires are a third twisted pair of electrical wires.    -   27. The electrical cable assembly of embodiment 15 wherein the        cable includes a fire resistant covering for the wires.    -   28. The electrical cable assembly of embodiment 15 wherein the        cable includes filler strands.    -   29. An electrical connector assembly comprising:        -   a first electrical connector including:        -   first electrical contacts, the first electrical contacts            conduct electrical signals;        -   a first insulator, the first insulator holds the first            electrical contacts;        -   a first grounding shell, the first grounding shell includes            a first slot, the first slot forms a first beam, the first            beam includes a first protrusion;        -   a second electrical connector including:        -   second electrical contacts, the second electrical contacts            conduct electrical signals;        -   a second insulator, the second insulator holds the second            electrical contacts;        -   a second grounding shell, the second grounding shell            includes a ramp and a detent, the first protrusion engages            the detent when the connectors are mated.    -   30. The electrical connector assembly of embodiment 29 wherein        the first grounding shell includes a second slot and a second        beam.    -   31. The electrical connector assembly of embodiment 29 wherein        the first grounding shell includes eight slots and eight beams.    -   32. The electrical connector assembly of embodiment 29 wherein        the detent is a groove.    -   33. The electrical connector assembly of embodiment 29 wherein        the first connector includes an inner shell.    -   34. The electrical connector assembly of embodiment 33 wherein        an insulator is located between the grounding shell and the        inner shell.    -   35. The electrical cable assembly of embodiment 29 wherein the        electrical cable includes one or more wires.    -   36. The electrical cable assembly of embodiment 35 wherein the        cable has a center, the one or more wires are located closer to        the center than a first twisted pair of electrical wires.    -   37. The electrical cable assembly of embodiment 35 wherein the        one or more wires are a third twisted pair of electrical wires.    -   38. The electrical cable assembly of embodiment 29 wherein the        cable includes a fire resistant covering for the wires.    -   39. The electrical cable assembly of embodiment 29 wherein the        cable includes filler strands.

The invention claimed is:
 1. An electrical connector assemblycomprising: a first electrical connector including: first electricalcontacts, the first electrical contacts conduct electrical signals; afirst insulator, the first insulator holds the first electricalcontacts; a first outer shell, the first outer shell has a longitudinalaxis, the first outer shell has a circular cross-section, the firstouter shell is located over at least a portion of the first insulator,the first outer shell includes a first slot, the first slot extendsalong the longitudinal axis the first slot forms a first beam, the firstbeam includes a first protrusion; a second electrical connectorincluding: second electrical contacts, the second electrical contactsconduct electrical signals; a second insulator, the second insulatorholds the second electrical contacts; a second outer shell, the secondouter shell has a circular cross-section, the second outer shell islocated over at least a portion of the second insulator, the secondouter shell includes a ramp and a detent, the first protrusion engagesthe detent when the connectors are mated.
 2. The electrical connectorassembly as in claim 1 wherein the first outer shell includes a secondslot and a second beam.
 3. An electrical connector assembly comprising:a first electrical connector including: first electrical contacts, thefirst electrical contacts conduct electrical signals; a first insulator,the first insulator holds the first electrical contacts; a first outershell, the first outer shell has a circular cross-section, the firstouter shell is located over at least a portion of the first insulator,the first outer shell includes a first slot, the first slot forms afirst beam, the first beam includes a first protrusion; a first innershell, the first outer shell is located over at least a portion of thefirst inner shell; a second electrical connector including: secondelectrical contacts, the second electrical contacts conduct electricalsignals; a second insulator, the second insulator holds the secondelectrical contacts; a second outer shell, the second outer shell has acircular cross-section, the second outer shell is located over at leasta portion of the second insulator, the second outer shell includes aramp and a detent, the first protrusion engages the detent when theconnectors are mated.
 4. The electrical connector assembly as in claim 3wherein the first outer shell includes a second slot and a second beam.5. The electrical connector assembly as in claim 3 wherein the firstouter shell includes seven additional slots and seven additional beams.6. The electrical connector assembly as in claim 3 wherein the detent isa groove.
 7. The electrical connector assembly as in claim 4 wherein thesecond beam includes a second protrusion.
 8. The electrical connectorassembly as in claim 5 wherein each of the seven additional beamsincludes a protrusion.
 9. The electrical connector assembly as in claim3 further includes an electrical cable, the electrical cable includesone or more wires.
 10. The electrical connector assembly as in claim 3further includes an electrical cable, the electrical cable includes afirst twisted pair of electrical wires, the electrical wires conductelectrical signals, a first shield covering the first twisted pair ofelectrical wires.
 11. The electrical connector assembly as in claim 10wherein the first shield is connected to the first inner shell.
 12. Theelectrical connector assembly as in claim 11 wherein the cable includesan outer shield which covers at least the first twisted pair ofelectrical wires and the first shield, the outer shield is connected toat least one of the first outer shell or the second outer shell.
 13. Theelectrical connector assembly as in claim 3 further includes a shellinsulator, the shell insulator is located between the first inner shelland the first outer shell.
 14. An electrical connector assemblycomprising: a first electrical connector including: first electricalcontacts, the first electrical contacts conduct electrical signals; afirst insulator, the first insulator holds the first electricalcontacts; a first outer shell, the first outer shell has a circularcross-section, the first outer shell is located over at least a portionof the first insulator, the first outer shell includes a first slot, thefirst slot forms a first beam, the first beam includes a firstprotrusion, the first outer shell includes seven additional slots andseven additional beams; a second electrical connector including: secondelectrical contacts, the second electrical contacts conduct electricalsignals; a second insulator, the second insulator holds the secondelectrical contacts; a second outer shell, the second outer shell has acircular cross-section, the second outer shell is located over at leasta portion of the second insulator, the second outer shell includes aramp and a detent, the first protrusion engages the detent when theconnectors are mated.
 15. The electrical connector assembly as in claim14 wherein the detent is a groove.
 16. The electrical connector assemblyas in claim 14 wherein each of the seven additional beams includes aprotrusion.
 17. The electrical connector assembly as in claim 14 furtherincludes an electrical cable, the electrical cable includes one or morewires.
 18. The electrical connector assembly as in claim 14 furtherincludes an electrical cable, the electrical cable includes a firsttwisted pair of electrical wires, the electrical wires conductelectrical signals, a first shield covering the first twisted pair ofelectrical wires.
 19. The electrical connector assembly as in claim 18further includes an inner shell, the first shield is connected to theinner shell.
 20. The electrical connector assembly as in claim 18wherein the cable includes an outer shield which covers at least thefirst twisted pair of electrical wires and the first shield, the outershield is connected to at least one of the first outer shell or thesecond outer shell.
 21. The electrical connector assembly as in claim 1wherein the detent is a groove.
 22. The electrical connector assembly asin claim 21 wherein the second beam includes a second protrusion. 23.The electrical connector assembly as in claim 1 further includes anelectrical cable, the electrical cable includes one or more wires. 24.The electrical connector assembly as in claim 1 further includes anelectrical cable, the electrical cable includes a first twisted pair ofelectrical wires, the electrical wires conduct electrical signals, afirst shield covering the first twisted pair of electrical wires. 25.The electrical connector assembly as in claim 24 wherein the firstelectrical connector includes a first inner shell, the first outer shellis located over at least a portion of the first inner shell, the firstshield is connected to the first inner shell.
 26. The electricalconnector assembly as in claim 25 wherein the cable includes an outershield which covers at least the first twisted pair of electrical wiresand the first shield, the outer shield is connected to at least one ofthe first outer shell or the second outer shell.
 27. The electricalconnector assembly as in claim 25 further includes a shell insulator,the shell insulator is located between the first inner shell and thefirst outer shell.